Torch for electric arc welding system

ABSTRACT

A torch for connection to an electric arc welding system having a wire feeder, a power source and a weld process controller for the power source. The torch being connected to the front end of a welding gun, which gun has a rear end with a first unique component of a connector. The welding system has a second component of the connector matching the first component. The gun has a communication channel extending from the torch to the first component for transmitting data to the welding system through the connector. The torch has a memory with an identification code outputted on the communication channel to the first component and the system has a decoder circuit connected to the second component and responsive to a selected identification code.

PRIORITY DATA & INCORPORATION BY REFERENCE

This application is a continuation of prior application Ser. No.11/210,286, filed Aug. 25, 2005, which is incorporated by reference inits entirety.

TECHNICAL ART

The present invention relates to electric arc welding and moreparticularly to a unique torch specially designed for increasing thetransfer of intelligence between the torch and an electric arc weldingsystem adapted to receive the torch.

BACKGROUND OF INVENTION

The invention involves the design of a unique torch for use with anelectric arc welding system where the torch has special abilities tocommunicate with the welding system and the system is adapted to receivethe torch. In Friedl U.S. Pat. No. 6,315,186 a special designed torchincludes an input device and a display device on the torch itself sothat a dedicated line is used to communicate data from the torch to theelectric arc welding system being used with the torch. The system canidentify the torch and change parameters of the welding processimplemented by the welding system. The parameters are changed on thetorch itself and are communicated by a single communication line to setand select parameters for the welding system. The alleged novelty is asingle communication line, but not details of the communicated data orthe response of the system to the data. This patent is incorporated byreference herein for its background technology and for the descriptionof a torch with an input device, as well as a torch mounted displaydevice. In a like manner, Kaufman U.S. Pat. No. 6,855,914 isincorporated by reference. The welding system identifies the impedanceof the torch to decide the type of torch connected to the weldingsystem, whether a push-pull torch or merely push torch. Identificationof the type of torch connected to the system is used to set a parameter,such as the motor speed for the wire driven through the gun or torch tothe welding operation. This background patent utilizes the system itselfto determine the type of torch and does not employ the torch as thesource of multi purpose intelligence to control the weld process of thewelding system. These two patents comprise the background to which thepresent invention is directed and disclose only primitive communicationbetween the welding torch and the welding system.

THE INVENTION

In the welding industry, the term “gun” is used in the welding industryto describe an elongated, flexible harness called the “cable” comprisingan isolation tube with a rear end connectable to a welding system of thetype including a wire feeder and power source with controller. The frontend of the “gun” has a torch to perform the welding operation. The terms“torch” and “gun” are often used interchangeably to mean either thewelding head or the whole unit. In this description the welding head iscalled a “torch.”

In accordance with the present invention the torch at the end of the gunis modified and especially designed to communicate with a welding systemalso designed for receiving the special type of torch. Thus, the torchhas a special design and the welding system has an input terminalstructure or receptacle communicated with special architecture andcomponents in the welding system to identify the special torch andreceive information in digital format from the torch. The information isused to operate the controller of the welding system. Consequently, inone feature of the invention, the torch includes an internal register ormemory having a unique digital identification code or other means tocommunicate its identity to a specially designed welding system. By (a)allowing the torch to identify its unique characteristics and/or itsspecific identity and (b) communicating data from the torch through adigital channel to the welding system, several unique capabilities aremade possible. The special torch and modified welding system constitutecompanion components facilitating communications between the twocomponents for the purposes of enhancing the overall efficiency of thewelding operation and improving the quality control and inventoryrequirements for the torch itself.

In accordance with one aspect of the invention, the torch is connectedto an electric welding system having a wire feeder with a feed motor, apower source and a weld process controller for the power source and thewire feeder to cause a selected welding process. The torch has a memorydevice for storing an identification code unique to the torch and atransmission line or communication channel to output the identificationcode in digital format. A unique receptacle with a plug and receptaclehaving a unique pin pattern allows connection of the torch, through anelongated tube or gun, to the welding system. The welding system towhich the torch is connected by a unique receptacle has a torchmonitoring device with an input terminal connected to the transmissionline or channel when the torch is connected to the system. Thismonitoring device has an input decoder circuit to identify the torch andto activate the monitoring program tailored to the particular torchbeing identified. In this aspect of the invention, the monitoring deviceincludes at least one accumulator for totaling a first torch use factorbased upon a selected weld parameter or combination of parameters. Acircuit is used to enable the accumulator when a specific torch isconnected to the input terminal of the weld system. The accumulator hasan output signal representing the total of the major parameter. Aprogram selected by connecting the specific torch creates or outputs alimit value for the use factor being monitored. A comparator network isprovided with a first input being the accumulator output signal and asecond input being the limit value from the selected program determinedby the actual torch connected to the welding system. The comparatornetwork creates an action signal when the output of the accumulatorreaches the limit value from the selected program. In this manner, thetorch is connected to the welding system and the monitor is operatedbased upon a selected program coordinated with a particular torch. Whena torch use factor being monitored reaches a given value, an actionsignal is created. The action signal indicates a corrective action to betaken, such as changing the liner of the gun, changing the contact tipof the torch or replacing and/or refurbishing the total torch.Consequently, whenever a given torch is connected to the welding system,a monitor measures one or more use factors. The use factors are storeduntil the next use of the particular unique torch. Ultimately, thetorch, either during a single application or subsequent uses of the sametorch, will pass a use factor limit value to identify an action to betaken, such as maintenance of the particular torch. In accordance withan aspect of the invention, the condition of the use factor can bedisplayed at the monitor or at a remote location by an hard wire or anethernet communication network. Consequently, whenever a torch isapplied to the welding system, the identification code is read by thewelding system and the monitor is initiated to accumulate a use factoror factors for the particular, unique torch.

In accordance with another aspect of the present invention, the torch,with a unique identification stored in memory or register, can alsoinclude a manually operated input device on the torch itself to createan output signal with digital data identifying a specific weld process.A communication channel directs data from the torch to the controllerwhere a circuit shifts the weld process of the controller. In thismanner, an input set circuit responsive to the digital data from thetorch sets the weld process of the controller to a specific weld processselected at the torch. In this embodiment of the invention, the weldprocess selected at the torch is based upon the type of process and thediameter and/or type of welding wire for the particular process. Thus,an operator indexes the torch between weld processes and diameters ortypes of wire at the torch itself. Then, the torch transmits such datafrom the torch to a set circuit of the controller so the controller isset to perform the process selected at the torch. Consequently, theidentification code stored in the torch is used to select the monitorand monitor the operation of the torch, while the torch itself is usedto set the particular weld process of the controller used forcontrolling the power source and/or the wire feeder.

The object of this aspect of the invention is the provision of a torchwhich has an identification code transmitted to the welding system foractuating a monitor to maintain information regarding historical use ofthe torch. Furthermore, the torch is provided with a process selector sothe operator can convert process data into digital information andtransmit such data through an information channel to the set circuit forthe power source controller of the welding system. Thus, the individualtorch is monitored and the torch is used, alternatively, to control theactual weld process performed by the welding system.

In a second embodiment of the invention, the torch does not have astored identification code, but it has a communication line or channeldirectly attached to the set input circuit of the power sourcecontroller. Consequently, by merely connecting the gun with a front endtorch to the welding system, the communication channel with thecontroller is established. The welding system in this embodiment of theinvention does not have a torch monitor, but has a controller with aninput set circuit that can be actuated by a gun having a particularinput communication line or channel designed to match the receptacle atthe input of the welding system. The rear end of the gun is connected tothe wire feeder using a special connector with matching plug andreceptacle. Consequently, in this second embodiment of the invention,the torch is merely connected to the electrical welding system. Thetorch has a set up device for manually selecting the welding parametersof the welding process and a line communicating the selected parameterin digital format to the torch itself. From the torch, the digital datais directed through a communication line coextensive with the tubecomprising the gun. The line extends from the torch to the controller tothereby set the parameters from the torch in the controller to performthe weld process. The set up device can be separate from the torch toadjust the value of parameters, such as wire feed speed, current andvoltage and accessories, such as the type of gas. These parameters andaccessories are loaded manually into the set up device which device isthen connected to the memory of the torch. The torch memory devicecommunicates this information to the input set circuit of the controllerin the welding system. A specially designed torch is necessary, sinceonly a special torch can have the communication line extending from aninternal memory device storing the parameters through the specialreceptacle of the welding system. In another application of thisconcept, the set up device is loaded with an identification code whichcan be used as defined above to enable the circuit for accepting datawhen the torch having such data is used. In accordance with an aspect ofthe invention, the set up device is a separate unit that merelyintroduces the set parameters and the torch identification code into amemory, such as through a touch memory button on the torch. The data isthereby loaded into the torch for subsequent use when the torch isconnected to a welding system. Connection is allowed by a communicationport in a connector on the system. This connector is unique to thecommunication line from the torch and includes a plug and receptaclewith a matching unique pin pattern. By using this second embodiment,other operating features can be incorporated with the torch.

In one implementation, a torch can be loaded with a set of parametersfor the weld process. Thus, whenever this torch is connected to thewelding system the controller is automatically set to perform thedesired weld process. This modification has an advancement where atoggle mechanism on the torch toggles between a plurality of sets ofparameters. Then the parameter set is selected by the toggle mechanismand is connected to the weld system. The controller is automaticallyshifted to the desired parameters. Another implementation involves apersonal parameter setting device or module. A welder has his ownmonitor. When he is ready to weld, he merely loads the parameters fromhis own module into a torch. The torch is thereby set to the parameterstailored by the welder. This loads these personal parameters into thecontroller by connecting the torch to the welding system by way of aspecial connector at the rear end of the flexible tube or gun.

A third embodiment of the invention involves a torch for connection toan electric welding system, as defined above. The torch has a registerwith a unique identification code, in digital format so that the torchis connected by communication channel to an interface module activatedby a given code and/or codes. One code that activates the interface isthe unique code of a particular torch connected to the welding system.The interface has an output that sets the weld process parameters. Theoutput channel of the interface transmits digital data to the controllerthat has a set up circuit for storing the transmitted digital data ascontrol parameters for the power source. Thus, by merely connecting aparticular torch to the welding system, the torch is identified and isallowed to activate an interface module. This module sets the parametersin the controller used by the welding system. The identification codefor the torch is in memory or register on the torch and is directedthrough a unique connector to the ID terminal of the interface module.The controller is set in response to the identification code stored onthe individual torch. Another aspect of such a torch is the setting ofthe weld parameters on the torch itself. The parameters are selected andoptionally displayed on the torch; however, they are also communicatedto the interface for the purposes of changing the parameters stored inthe interface modules. Thus, the torch is identified and activates theinterface to operate the controller. As an option, the torch itself isnormally adjusted to change the output parameter of the interface.Consequently, the torch by being connected to the welding systemactivates an interface to set the controller to the desired parameters,which parameters may or may not be changed manually by a welder at thetorch itself.

In accordance with a fourth embodiment of the invention, a unique torchdesign is provided wherein the torch itself can include a monitoringsystem. A first sensor in the torch measures the level of arc currentand a second sensor in the torch also measures the level of the wirefeed speed to the torch. These measurements multiplied by time areaccumulated to create use factors as explained in connection with thefirst embodiment. A memory unit associated with the torch itself storesthe use signal or signals and a monitor reads the use signals. Thismonitor can be in the form of a touch memory button. The use factorinformation is stored on the torch and is read from the torch ordisplayed on the torch. Consequently, the torch can be interrogated todetermine how much use it has experienced and whether it is capable fora subsequent, long term welding application. By this embodiment of theinvention, the torch carries with it a use history which is readabledirectly or indirectly from the torch. This ability to know the usehistory of a torch is of substantial benefit for inventory control.Furthermore, it prevents a torch from being placed into an applicationfor which it does not have residual life to complete.

A fifth embodiment of the invention is a torch with a uniqueidentification code stored in the torch itself. This code is used with acontroller including a closed loop circuit to control the weldparameters, such as current and/or voltage and a network to create aspecial weld procedure. The torch, with the unique identification codestored on the torch, creates an output signal which is decoded foridentification by the welding system. Receipt of the proper code createsa network enabling signal. This can be accomplished by connecting thelead carrying the unique identification code from the torch to thewelding system. By attaching the novel torch, the network enablingsignal is created by a decoded identification of the proper torch. Thissignal activates the network and converts the controller to the specialweld procedure. In this manner, a particular torch designed for a givenspecial operation of the controller is the only type of torch which canactivate the special alternative weld procedure. This embodiment of theinvention assures that a special torch is used when a special weldingprocess is implemented by the welding system.

These and other designs of the torch for a welding system are aspects ofthe present invention which will be described in more detail later. Theoriginal claims are incorporated by reference herein as disclosure.

The primary object of the present invention is the provision of a torchfor an electric welding application, which torch is coordinated with thewelding system. When the torch is connection to the system, the torchcommunicates with the welding system to facilitate accurate monitoringof the torch and/or proper welding using a specific torch.

Another object of the present invention is the provision of a torch, asdefined above, which torch has a stored digital identification codeindicative of either the particular torch itself for the purposes ofinventory and maintenance or a type of torch for the purposes ofcoordinating the operation of the torch with the welding system and/ormodifying the welding process performed by the welding system. The useof a novel torch that communicates with the welding system to performdiverse operations and function is the overall object of the invention.

Yet another object of the present invention is the provision of a torch,as defined above, which torch transmits an identification code to starta monitor associated with each individual torch. The monitor storesinformation based upon operation of the torch for the purposes ofsubsequent inventory and/or maintenance of the torch. Furthermore, suchtorch, with a stored identification code, has the desiredcharacteristics required by a particular welding system to which thetorch is connected and for performing a desired welding process.

Another object of the present invention is the provision of a weldingtorch, as defined above, which welding torch transmits digitalinformation from the torch to the welding system. The information isreadable only by a dedicated welder having an input connector comprisinga receptacle and port with matching pi patterns. The connector allowsthe system to receive and process transmitted digital information fromthe torch.

Still a further object of the present invention is the provision of atorch, as defined above, which torch includes a monitor or a torchmounted monitoring device to record and store the history of aparticular torch based upon use factors so a torch with very little lifewill not be used in an application requiring long term operation. Thus,the invention avoids mismatching of a torch history and the applicationto which the torch is intended.

Still a further object of the present invention is the provision of awelding torch, as defined above, which welding torch is used to activatea unique specially designed welding system through the setting ofparameters in the power source controller or otherwise.

Yet another object of the invention is the provision of a torch which isloaded with desired weld parameters so when the torch is connected tothe weld system the system is programmed by the torch. Thee loadedparameters can be adjusted and carried with the torch.

A further object of the invention is the provision of a torch which canbe programmed by an operator with a personalized set-up unit or moduleso the operator merely loads a torch when he is ready to use the torch(any torch) for a given weld process.

These and other objects and advantages will become apparent from thefollowing description taken together with the accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic, combined wiring and block diagram illustrating afirst embodiment of the present invention;

FIG. 2 is a schematic illustration of certain structures employed in theembodiment shown in FIG. 1;

FIGS. 3 and 4 are block diagrams illustrating representative techniquesfor loading identification codes into the torch shown in FIGS. 1 and 2;

FIG. 5 is a schematic, combined wiring diagram and block diagramillustrating a second embodiment of the present invention;

FIG. 6 is a schematic, combined wiring diagram and block diagramillustrating a third embodiment of the present invention;

FIG. 7 is a schematic, combined wiring diagram and block diagramillustrating a fourth embodiment of the present invention; and,

FIG. 8 is a schematic, combined wiring diagram and block diagramillustrating a fifth embodiment of the present invention.

PREFERRED EMBODIMENTS

In electric arc welding applications, a torch is located on the frontend of an elongated flexible tube called a “gun” connected by aplug/receptacle with a welding system. Such system normally includes awire feeder and a power source provided with a controller to operate thepower source and/or the wire feeder to move welding wire through the gunand the torch to the welding operation at a desired wire feed speed withthe desired voltage and current characteristic to perform a specificwelding process dictated by the setting of the controller. The presentinvention involves novel torches, each of which is combined with amodified welding system that accommodates the torch and communicate withthe torch in novel combinations of elements. These torch/welding systemcombinations facilitate the welding operation by using intelligencesupplied by the torch. The torches of this invention each have a specialdesign different from common torches normally used in the weldingindustry.

The first embodiment of the invention is shown in FIGS. 1 and 2 whereinspecially designed torch T has a handle, illustrated as a broomsticktype handle 10, with an outwardly extending gooseneck 12 terminating ina lower nozzle 14 through which welding wire W is pushed towardworkpiece WP to perform a welding process between welding wire W and theworkpiece WP. As is normal in the welding industry, welding system A iscommunicated with torch T and includes a wire feeder 20 having a supplyof welding wire 22 pulled by feed rolls 24 driven at a wire feed speeddetermined by motor 30 under the control of microprocessor 32. Themicroprocessor receives wire feed speed commands through control lead 34normally connected to wire feeder 20 and having an internalmicroprocessor control chip not illustrated. To provide current for thewelding operation, system A includes power source 40 with controller 42having output lead 44 for controlling the operation of the power sourceand lead 46 for controlling the operation of wire feeder 20. Thecontroller itself can provide the information on lead 34 to set thespeed of the motor 30 so the desired wire feed speed is used inaccordance with the needs of the particular welding process beingperformed by system A. Torch T is connected to the front end of theelongated, flexible cable or gun G having an outer sheath coveringdesignated leads 60, 62 which leads constitute a unique structure to thepresent invention. Gun G also houses moving welding wire W and powerlead 70 as is common in the welding industry. The rear end of elongatedgun G is connected to system A by special connectors 80 a, 80 b toaccept the special designated lead 60, 62. The connectors are one unitwith a plug and receptacle with matching pin patterns. The gun also hasa trigger lie to start the welding operation. Of course, the gun alsoprovides a gas passage for shielding gas to be provided at the weldingoperation if the welding operation is not self-shielding. As so fardescribed, torch T and system A are standard welding components exceptfor the designated lead 60, 62 and the special combined connectors 80 a,80 b used to accept the rear end of gun G carrying not only a wire W,power lead 70 and a gas conduit, but also designated leads 60, 62. Inoperation, controller 52 operates wire feeder 20 and power source 40 fordriving wire W through torch T as a designated welding process isperformed. The process has specific parameters, such as current voltageand wire feed speed dictated by the setting of controller 42. Into thisstandard architecture, the present invention is incorporated.

In accordance with the invention, torch T includes an internal memory orstorage register 100 for storing an identification code. The code isindicative of particular unique torch T. By depressing transit button102, the unique torch specific digital code in memory or register 100 istransmitted through designated line 60 to portion 80 a of the combinedconnector. This connector is at the input of monitor M for monitoringthe operation of the unique torch T. Monitor M includes a digitalprocessing device, such as a DSP or microprocessor, to perform thefunctions hereinafter explained after receipt of digital data fromcontroller 42 by way of inputs 110 and 112. Input 110 reads andretrieves appropriate data from wire feeder 20, while input 112 readsand retrieves appropriate data from controller 42. This data isprocessed by monitor M to generate information regarding the operationof torch T. The torch information is used for servicing and inventorypurposes associated with the particular unique torch T. Monitor M has aninternal digital decoder 130 connected to the input of connector portion80 a. The decoder outputs on line 130 a the identity of the particulartorch T connected to connector portion 80 a. This information isgenerally related to the specific torch. It is directed by lead 130 a toa select table routine or program 132 so that data on output line 134identifies unique specific torch T. This information is directed by line134 a to a look up table 120 storing a multiple of programs, each ofwhich includes a limit value for a torch of the general type used as thespecific unique torch T. To assure that only that type of torch iscapable of communication with monitor M, line 60 is communicated to apassword circuit 140 set to a series of different types of torches thatare capable of activating monitor M. This type of special torch T isprovided by program 142 so that the information on line 60 passed to theidentification digital decoder 130 is the identity of torch T and theparticular type of the torch. This password of the type of torch can beprovided at register 100 as described in FIG. 3. Monitor M is informedof the specific torch T and the type having values stored in lookuptable 120. Monitor M also includes an internal memory 150 connected byline 152 to the input decoder circuit 130 to obtain he identity of thespecific torch. Thus, memory 150 stores information specific to theunique torch T. Memory 150 writes the identification code from memory100 into a register and accumulates information developed by monitor Mfor the particular torch. The memory 150 has I/O line 154 to input andstore information relating to the particular unique torch T and tooutput this stored information associated with a particular torchidentified by the input decoding circuit 130. The stored data of aparticular torch is outputted on I/O line 154. When torch T is a newtorch or has been refurbished and therefore requires clearing ofexisting stored information in memory 150, the memory is reset by aprogram represented by gate 160 having output line 160 a. A reset logicon line 160 a resets memory 150 for the particular torch identified bythe digital data on line 152. Gate 160 has a first input line 162 fromdecoder 164 for decoding the digital information on line 140 a andproviding a logic 1 on input 162 for the particular torch T connected toconnector portion 80 a. The other input to gate 160 is the logic on line170 from the reset program 172. The program produces a logic 1 on line170 when a new or refurbished torch T is first used in the combinationillustrated in FIG. 1. Thus, the information on line 154 is theaccumulated information for a particular torch T. When a new torch isused, a reset signal on line 160 a resets memory 150 for the new torch.Monitor M then monitors the operation of the new unique torch T.

Monitor M has an internal program for monitoring the operation of eachspecific torch T identified by the code data, appearing in line 152. Thetype torch from the input code activates line 130 a to select a programstored in lookup table 120. A variety of program architecture can beused for monitoring various conditions of torch T; however, in thisfirst embodiment of the present invention, as illustrated in FIG. 1,communication line 154 reads the accumulated stored values for the torchidentified by line 152 and writes additions to these stored values. Thisupdate procedure for historical data for unique torch T is obtained byoutputting particular limit values for various parameters associatedwith the type of torch selected by password device 140. These limitvalues are outputted from lookup table 120 on line 200 and are separatedby output circuits, not shown, for value limit select lines 200 a, 200b, 200 c and 200 n. The data on these lines control comparator networks210, 2121, 214, and 216, respectively. Thus, the comparator networksmonitor certain limit values from lookup table 120 associated with aparticular type of torch and these limit values are used in the outputprogram P of monitor M for the specific torch T identified by data online 152. Comparator networks 210-216 have associated digitalaccumulators 220, 222, 224 and 226, respectively. In practice, at leastone accumulator and comparator is used for practicing the firstembodiment of the invention; however, preferably several comparators andaccumulators are used so that many historical and operationalcharacteristics of torch T can be monitored simultaneously. Theaccumulators are driven by inputs 230, 232, 234 and 236, respectively,driven by parameters and/or events. Thus, the action signals on outputlines 240, 242, 244 and 246 indicate when the associated comparatorchanges logic because the accumulator associated with the comparatorexceeds the limit values outputted from lookup table 120. The actionsignal logic on lines 240, 242, 244 and 246 activate actionidentification registers 250, 252, 254 and 256, respectively. The stateof these action registers is shown on associated display devices 250 a,252 a, 254 a and 256 a, preferably located on a remote console; however,they can be associated with the welding system or actually displayed onthe torch itself. All of these implementations of program P are withinthis first embodiment of the present invention. In the illustratedembodiment, the wire feed speed from the magnitude signal on line 34 ismultiplied by time and directed by input line 260 to comparator 210.Thus, when the accumulated wire feed speed and time product reaches agiven level from lookup table 120 as it appears on line 200 a, the logicsignal on line 240 changes state and records an action which, in thisexample, is a “replace tip” action. Thus, the amount of wire fed to thetorch is used to determine when the contact tip of the torch should bereplaced. In a like manner, the logic on line 240 is also directed toaction identification register 260 by line 262. This action registerindicates that the torch should be replaced. This action is revealed bydisplay device 260 a. In practice, either line 240 or line 262 is usedto determine the action to be taken when a certain amount of wire hasbeen driven through the torch T. Either the tip is replaced or the torchis replaced according to the particular action identification signalemployed. Whenever motor 30 is started, the event is recorded inaccumulator 222. A certain number of start events indicates when the tipshould be replaced. When this number is reached, the logic on line 242is shifted to display a replace tip action requirement for torch T. Insome instances, it is advantageous to measure the current of motor 30.Increased motor current is generally caused by liner friction inelongated gun G. Liner friction is the characteristic controlled bycomparator network 214. Increase in the current of motor 30 is recorded.When the current reaches a certain level, the logic changes on line 244.In this instance, the accumulator 224 is merely recorded. When thecurrent of motor 30 reaches a certain level, as found outputted from thelookup table for a particular type torch T, the logic on line 244shifts. This indicates that the liner for torch T should be replaced.This is the message of action register 254. Thus, the parameters oftorch T monitored by monitor M can either be an arithmetic magnitude oran accumulated level. A generic use of the present invention forparameters is indicated by the last example. Comparator network 216 isactuated by any parameter “n” associated with use of torch T. Theaccumulated amount of parameter n is compared to a level or value forparameter n on line 200 n. This generic parameter can be currentmultiplied by time to indicate the amount of energy processed by theunique torch T. Other parameters are within the intent and scope of theinvention. The parameters and events shown in FIG. 1 are onlyrepresentative of the nature and of the type of historical informationof torch T contemplated in practice at this time. Whenever torch T isconnected to the welding system A, the output from I/O line 154 updatesall of the accumulators to the value stored in memory 150 for theparticular torch. Memory 150 maintains a history of torch T for each ofthe parameters and events in program P. When the torch has beenrefurbished or a new torch is inserted with the same identificationnumber, memory 150 is reset by a program represented by gate 160, aspreviously described.

In accordance with an aspect of the invention, monitor M also provideslife meter 300 determining the remaining anticipated life of the torch Tbefore it should be replaced. Life meter 300 includes register 302 thatdecreases from 100% to 0% by sensing the output of one of theaccumulators. As illustrated, the accumulator 220 is read by line 304,together with the limit value for the product of wire feed speed andtime. This value appears on line 306. The output of register 302indicates the amount of life remaining for the particular torch T. Thislife percentage is displayed by device 308 or is recorded on torch T orwith respect to torch T for future use in inventory management. ProgramP can take other forms; however, the computer program, as described, isthe preferred implementation of the first embodiment of the invention.

In accordance with another aspect of torch T, it has a separate anddistinct function wherein the torch is connected to the welding system Ato provide parameters on designated line 62. Parameters, in digitalformat, are selected in torch T and transmitted by line 62 to set-upcircuit 50 of controller 42. In this separate and distinct function oftorch T, the torch is a companion to system A. Communication lead 62,runs through elongated gun G from the front end at torch T to the rearend at connector portion 80 b. Since system A has receptacle componentof connector portion 80 b, it can communicate with torch T by designatedline 62. This line communicates parameters that are used by controller42 to cause the desired selected welding process to be determined byinformation from torch T. In accordance with this feature of the firstembodiment, torch T is constructed as shown in FIGS. 1 and 2. An indexdevice 320 progresses through menu 322 by index commands on line 320 a,as best shown in FIG. 2. The menu indexes between the process to beperformed and the diameter or type of wire to be used. According to theindexed position on menu 322, a signal through line 332 corresponds tothe desired process and wire diameter and/or type and is provided frommenu 322. This data signal is communicated with a programmable setcircuit or memory 330. This set circuit or memory outputs parameters,such as current, voltage and wire feed speed, by line 334 to designatedcommunication channel 62. In this way, parameters selected on the torchare communicated to input set up circuit 50. Thus, torch T is modifiedto set the welding process wire size and/or wire type by creatingparameters used by controller 42 during the welding process. This is aseparate and distinct feature associated with torch T. In accordancewith this feature, the torch has a manual set up device or storagememory 330. This device stores the welding parameters for a givenwelding process as provided by the index position of menu 322. Line 334communicates the selected, stored parameters from device 330, in digitalformat, to line 62 for communicating the stored parameters from thetorch to controller 42. This structure sets parameters into theprocessing unit of controller 42 by circuit 50. Thus, parameters storedin torch T are used by the controller to implement a desired weldingprocess. The same torch has an identification code in register 100 whichis communicated with the controller through monitor M. In practice, menu322 and menu indexer 320 are part of the torch; however, they can beseparate from the torch.

As shown in FIG. 1, password device 140 adds to the identification codea password for the classification or type of torch attached to system Aby connector 80 a, 80 b. In FIG. 3, this torch type code is loaded intoidentification register 100 from a password device 340 by transmitdevice 342. In a like manner, the register 100 a can be a read onlymemory which is loaded at the manufacturer and read from line 60 to setdecoder 130 of monitor M. The manufacturer can also load a type codewith a torch identification code in read only memory 100 a. These twomodifications of the code read/write register 100 and read only memory100 a are illustrated in FIGS. 3 and 4. These showings arerepresentative of various schemes for loading the torch code and typecode into the data storage device in read only memory 100 a forcommunication from torch T to system A. Other minor changes in the firstembodiment of the invention shown in FIGS. 1 and 2 and the modificationsregarding communication of parameters to system A can be made withoutdeparting from the intended spirit and scope of the first embodiment ofthe invention.

The present invention involves connecting a specially designed torchwith a specially constructed welding system so that communication occursbetween the torch and system to enhance overall efficiency and controlof the welding process accomplished by operating the welding system. InFIG. 5, a second embodiment of the invention is illustrated. This is thepreferred embodiment. Unique torch T1 has set up devices for manuallyselecting weld parameters for the welding process. A line 472communicates selected parameters, in digital format, to the torch T1.Line 414 communicates the torch stored parameters, in digital format,from torch T to the controller 460 whereby the torch stored parametersare used by the controller to implement the process. To accomplish thisobjective, the rear end of the gun G1, including torch T1, includes aconnector 420 with a plug 422 matching a companion adapter 424 on thewelding system. Thus, the relationship between torch T1 and system A1 issuch that the torch can control at least some of the parameters used inthe welding system. These parameters are manually set, at the torch, byselector device S.

Details of this second embodiment of the invention are shown in FIG. 5.Torch T1 has handle 40 terminating in gooseneck 402 with end nozzle 404.This torch is the front end of elongated gun or cable G1 housing powerlead 412, welding wire 412 and communication line or channel 414. Ofcourse, gas is communicated through gun G1 to torch T1 when shieldinggas welding is being performed. To assure that the proper torch isconnected to dedicated welding system A1, a connector 420 has an inputside or plug 422 at the rear end of gun Gland an output side orreceptacle 424. This connector is used at the intersection between gunG1 and welding system A1. The prong or pin pattern of input 422 matchesthe prong or pin pattern of output 424. Consequently, the proper torchand system are connected. The attributes and features of novel torch T1are, thereby, facilitated. In accordance with somewhat standardpractice, welding system A1 includes wire feeder 430 having a supplyreel 432 of welding wire W. The wire is pulled over capstan 434 by feedrolls 436 to push wire W through gun G1 to torch T1 at a speed WFSdetermined by wire feed motor 438 controlled by a microprocessor inaccordance with the description of the first embodiment illustrated inFIG. 1. Contactor 440 is standard and includes solenoid 442 to activatecontactor 440 when the trigger (not shown) on handle 400 is depressed toclose contactor 440. Of course, a trigger lead passes through gun G1when the torch is used for a manual welding operation. The startersystem for automatic welding, such as used with a robot, merely closescontactor 440 by a solenoid 442 in accordance with a start signal. Whencontactor 440 is closed, lead 444 which is an extension of power lead412 is connected to lead 446 from power source 462. Wire feeder 430 alsoincludes an input set circuit 450 which may or may not have a codeenabling front end, but does have an input 452 which is an extension ofcommunication line 414 and an output line 454, which is a line connectedto controller 460 for power source 462. Thus, lead 454 from circuit 450sets selected parameters or operating features of power source 462 byinputting digital information to controller 460. Power source 462outputs welding current on line 446. Parameters necessary for performinga selected welding operation between wire W and workpiece WP are storedin torch T1.

In accordance with the second embodiment of the invention, torch T1includes a digital register 470 having a write line 472 to write datainformation into the register from selector device or set up device Sand a read line 470 a attached by connector 470 b to communication line414. Devices can be part of the torch or a separate unit as illustratedin FIG. 5. Buttons 480, 482 and 484 are capable of setting certain weldparameters, such as wire feed current and voltage, for communicationwith controller 460 by line 414 from torch T1. Furthermore if aparticular gas is to be employed, button 486 is adjusted to select thedesired gas, which is normally CO2 and/or argon. Optionally, this buttoncan adjust the rate of flow of the gas, as digital data, loaded intoregister or memory device 470 through write line 472. If a separateunit, device S has output terminal 472 a for information transfer toline 472. When using torch T1, set up device or selector device S ismanually adjusted by buttons 480, 482, 484 and 486 to provide thedesired parameter for the welding operation of system A. Representativeparameters are illustrated; however, a person skilled in the art couldselect other parameters to be controlled by a manual loading of register470 on torch T1. In some implementations of this second embodiment,device S includes a button 490 for creating an identification code thatis also written or loaded into register 470 to be communicated to thefront end of set circuit 450. This code identifies a type of torch, butnot a specific torch. By using this type code, set circuit 450 has adecoder front end and is enabled only upon receipt of a given type codeby way of line 414 from memory register 470. This second embodiment ofthe invention allows adjustment of the desired welding parameter at thetorch, either by a unit S formed integrally with the torch or by aseparate unit S remote from the torch. A remote unit communicates withthe torch by read line 472 a during the setting operation.

The second embodiment provides unit capabilities. By storing parametersin register 470, torch T1 will automatically load parameters intocontroller 460 by merely connecting the torch to the welding system. Toenhance this capability, a toggle mechanism 474 indexes menu storagedevice 476 to change the parameters stored in register or memory device470. Device S can be a personalized POD which is loaded by a welder to adevised parameter set. Thus, the welder merely selects a torch and loadshis parameters through line 472. Torch T1 will always be set into acondition preferred by the welder.

By using the invention a set of parameters can be loaded into any torchso the torch controls the weld process. In an alternative, the storedparameters of a torch can be changed as desired by any weld process.Other capabilities will be apparent to a person skilled in the weldingart.

A third embodiment of the present invention is illustrated in FIG. 6.This embodiment is somewhat similar to the second embodiment of theinvention shown in FIG. 5 and has a common welding system and involvesthe same input set circuit 450. Attachment of torch T2 activates adesired welding process with selected parameters. To accomplish thisobjective, torch T2 includes a handle 500 having an outwardly projectinggooseneck 502 terminating in nozzle 504 for performing the weldingoperation between wire W and workpiece WP. In accordance with thisembodiment, the rear end of the gun is connected to an interface module510 having a storage output section 512 and an input identificationcircuit 514 to activate storage section 512 when receiving a selectedcode appearing on line 516 extending through the gun frp, torch T1. Thisgun is modified to communicate the identification code by line 516 whenthe torch is connected to the welding system. Thus, mere connection ofthe torch causes the input section 514 to activate interface module 510for outputting digital data from section 512 on line 518. The datachanges the parameters in set circuit 450 which is the same set circuitas shown in FIG. 5. Interface 510 is activated, in the preferredembodiment, by merely connecting line 516 to the module; however, in apractical implementation, line 516 is a communication channel betweentorch T2 and interface module 510 and receives digital data code fromregister 520 of torch T2. This register in one implementation merelystores a code. A code in digital format is communicated between register520 and input identification circuit 514. In this implementation of thethird embodiment, merely connecting torch T2 to the welding systemactivates module 510 because the code from the torch is identified byinput circuit 514. In summary, section 512 is activated in one exampleby merely connecting the torch to the interface at the input side of thewelding system. As illustrated, section 512 is activated by section 514reading a specific code from the attached torch. Thus, the code for anytorch used in these examples must have a special connector 510 a. In thesecond example it must also have the ability to transmit a coderecognizable by decoder section 512 of interface 510.

In accordance with another aspect of this third embodiment, storagememory register 520 is a read/write register so parameter togglemechanism 522 is toggled to select desired parameters, such as theparameters shown in device S of FIG. 5. These parameters, after beingselected and stored in memory circuit 524, are written into storagememory or register 520 from set circuit 524 by write line 526. Inaccordance with another aspect, handle 500 includes a register 530 todisplay the selected parameters on visual device 532. The visual data isbased upon the data received from set circuit 524 through write line534.

The third embodiment employs an interface module 510 that storesparameters for the welding process to be performed by the weldingsystem. Module 510 has a front end for activation of the interface onlywhen the front end receives selected input code from torch T2 attachedto the front of the module. Torch T2 has a stored identification code inregister 520 wherein the stored code matches the selected input code ofcircuit 514. By communication of a proper code from torch T2 to circuit514, module 510 is activated. As a further aspect torch T2 has structureon the torch which structure includes a device for changing the storedparameters in section 512 of module 510. In a simplified version, thecode concept is replaced by merely actuating the module by attaching thetorch.

The fourth embodiment of the present invention is illustrated in FIG. 7.Welding torch T3 is attached to welding system A1, as shown in FIGS. 5and 6 and having wire feeder 430 and a power source 462. Torch T3comprises handle 550 with gooseneck 552 and terminal end nozzle 554 andis connected to system A1 by gun G3 terminating in connector 560 havingan input plug 562 and an outlet receptacle 564. This same type connectoris used in the other embodiments of the present invention. The plug andreceptacle have matching prong or pin patterns to assure componentmatching for proper coordination between the torch and the weldingsystem. In this fourth embodiment, torch T3 includes a first sensor 570for sensing a parameter illustrated as the welding current. Secondsensor 572 senses another parameter indicated as wire feed speed. Thesetwo parameters are representative in nature to define the inventivecharacteristics of this embodiment. The sensors are coordinated withtimer 574 so output lines 580, 582 and 584 have a combined parameter andtime signal. Multiplication circuit 586 multiplies the value of arccurrent on line 580 by time of the current flow based upon reading fromtimer 754 as indicated by line 584. Thus, the output of circuit 586 online 586 a is the arc current multiplied by time during which currenthas been flowing through torch T3. In a like manner, multiplicationcircuit 588 multiplies a second parameter, indicated to be wire feedspeed, by the time on line 584 so the value on output line 588 a is theaccumulated amount of wire fed through torch T3. Consequently, themagnitude of signals on lines 586 a and 588 a are indicative of usefactor measurements for torch T3. These use factor measurement signalsare accumulated in accumulator 590 and are read and reset by a memorydevice, shown as touch memory 592 through line 592 a. Consequently, usefactor signals accumulated for the two use related conditions arereadable from storage and output device 592. The storage and outputdevice is interrogated by monitor unit 600 containing stored levelsassociated with the two use factor signals from accumulator 590. Thisstructure is similar to the structure and function illustrated anddiscussed with respect to the invention shown in FIG. 1. Comparatornetworks 602, 604 and 606 read the accumulated use factor signals inaccumulator 590 by way of storage and memory device 592 to create actioncommands that are displayed on device 610, 612 and 614. In this manner,monitor unit 600 reads the use factor signals for torch T3 and displaysthe actions to be taken with respect to this torch. Unit 600 can bemounted at a remote console or at the welding operation. Accumulator 590maintains the history of the use criteria for torch T3 until theaccumulator is selectively reset. Reset is accomplished by a button 620on monitor unit 600. Upon depressing button 620 and connecting unit 600with accumulator 590 as illustrated by line 600 a, accumulator 590 isreset for the particular torch T3. In this manner, the history of thetorch T3 is maintained until the torch is refurbished or otherwiserehabilitated. Torch T3 has sensors 570, 572 to measure the level ofcurrent and the wire feed speed. It also has a timer 574 and a circuit586 or 588 to combine one of more of these measurements as a product oftime to develop one or more use factor signal or signals. Memory unit592 accumulates the use factor signals so monitor unit 600 can read theuse factor signals selectively for a given torch.

The fifth embodiment is schematically illustrated in FIG. 8. Weldingtorch T4 has a handle 640 connected by gun G4 to welding system A4 whichincludes a wire feeder 650 and a power source 660. Power lead 652 isdirected from power source 660 through wire feeder 650 to the power lead664 in gun G4. Power source 660 is operated in accordance with standardpractice with a standard controller. Arc current 662 is set by circuit664. In a like manner, the arc voltage stage 666 is set by circuit 668.As so far described the controller of the power source 660 and also wirefeeder 650 operates in accordance with standard practice by eithercurrent or voltage feedback. To illustrate the inventive nature of torchT4, power source 660 has a separate and distinct operating system,illustrated as a system using waveform generator 670 to process aselected waveform program from one of the stored programs in module 672.Thus, the power source has a standard operating procedure and a secondcontrol arrangement illustrated as a network including a waveformgenerator and other related well known components for using a waveformgenerator. See Fulmer U.S. Pat. No. 6,498,321 which is incorporated byreference. Network including generator 670 is enabled by a signal inline 674. To create this signal for shifting from standard operation tothe special network operation, novel torch T4 is employed. Handle 640includes a stored identification code in read/write register 680 whichis communicated by line or channel 682 through the gun G4 to the weldingsystem A4. The input of the welding system for line 682 is a connector684 having a unique plug and matching receptacle. The same connector isillustrated as connector 654 at the input feeder 650. The uniqueconnector 684 directs the coded digital information on line or channel682 to the input side of welding system A4 illustrated as decoder 690.When the proper signal is received by decoder 690 an enable signal inline 674 activates special process network 670. By using torch T4attached to welding system A4, power source 660 is converted from astandard control operation to a higher level control protocol. Thus, gunG4 having a front end terminating at torch T4 is connected to weldingsystem A4. The system automatically shifts into a high technologycontrol protocol. The use of the high level protocol is indicated byline 676 extending from network 670. If this protocol is deactivated, asignal is directed to circuit 678 to shift from the high protocol to thenormal operation for power source 660.

Several embodiments are described. It is intended that structuralarrangements from any of these embodiments can be used in the otherembodiments to develop a unique arrangement of a novel torch and awelding system coordinated with the torch to communicate information andcontrol the operation of the welding system.

Having thus defined the invention, the following is claimed:
 1. Awelding system comprising: a wire feeder apparatus, a supply of wirewherein the wire is fed through the wire feeding apparatus, a gunthrough which the wire passes, said gun having a memory switch; and acontrol device which controls the feeding of the wire through thefeeding apparatus based upon input from a user input device positionedon at least one of the wire feeding apparatus and the brazing wire gun,wherein said control device has at least one memory space, said memoryswitch being configured with said at least one memory space forrecording at least one welding parameter to said memory space.
 2. Thesystem of claim 1, wherein the at least one welding parameter includesat least one of a diameter of said wire, a material of said wire, a wirefeed speed, and a duration of a wire feeding operation can be input bysaid user input device.
 3. The system of claim 1, wherein said guncomprises a trigger portion to activate said wire feeding operation. 4.The system of claim 3, wherein said trigger portion has a first positioncorresponding to a first wire feed speed and a second position whichcorresponds to a second wire feed speed.
 5. The system of claim 3,wherein said trigger portion controls said wire feeding operation basedon the movement of said trigger portion, wherein there is a non-linearrelationship between the movement of the trigger portion and the wirefeed speed of the wire.
 6. The system of claim 1, wherein said guncomprises a trigger to activate the feeding of said wire and at leastone second control portion which controls a speed of the feeding of saidwire.
 7. The system of claim 1, wherein said at least one brazingparameter includes feeding the brazing wire through the brazing wirefeeding apparatus.
 8. The brazing apparatus of claim 7, wherein said atleast one parameter is one of wire feed speed, a length of wire, and awire feed duration.
 9. A system, comprising: a wire feeding apparatus, asupply of wire wherein the wire is fed through the wire feedingapparatus, a gun through which the wire passes, and a control devicewhich controls the feeding of the wire through the feeding apparatusbased upon input from a user input device positioned on at least one ofthe wire feeding apparatus and the wire gun, wherein said wire guncomprises a trigger to activate said wire feeding operation, and whereinsaid trigger controls said wire feeding operation based on the movementof said trigger, said control device having at least one memory spaceand at least one memory button configured with said memory space to anyone of select or store a plurality of process parameters.
 10. The systemof claim 9, wherein at least one of a diameter of said wire, a materialof said wire, a wire feed speed for said wire, and a duration of a wirefeeding operation can be input by said user input device.
 11. The systemof claim 10, wherein said trigger portion has a first positioncorresponding to a first wire feed speed and a second position whichcorresponds to a second wire feed speed.
 12. The system of claim 10,wherein there is a non-linear relationship between the movement of thetrigger portion and the wire feed speed of the brazing wire.
 13. Thesystem of claim 10, wherein said gun controls a speed of the feeding ofsaid wire.
 14. The system of claim 10, wherein said plurality ofparameters includes feeding the wire through the brazing wire feedingapparatus.
 15. The system of claim 14, wherein said plurality of brazingparameters includes one of wire feed speed, a length of wire, a wirefeed duration and a wire feed pause time.
 16. A programmable systemcomprising: a wire feeding apparatus for feeding a wire, a gun, and acontroller for programming a plurality of welding operations, saidcontroller controls the feeding of the wire through the feedingapparatus based upon input from an index device positioned on at leastone of the wire feeding apparatus and the gun, wherein said guncomprises a trigger to activate said wire feeding operation, whereinsaid trigger controls said wire feeding operation based on the movementof said trigger portion, wherein each operation is defined by at aplurality of parameters including at least one of a diameter of saidwire, a material of said wire, a wire feed speed for said wire, and aduration of a wire feeding operation can be input by said index device,and wherein said controller comprises at least one memory spaceconfigured with said index device to store said plurality of parametersto program said apparatus.